Air Hoist Safe Practices and Procedures Power Point

Morgan City Rentals
Procedures and Practices
Air Hoist
Air Hose
Main Service Areas of the Hoist
Throttle Handle
Brake Handle
Forward /
Reverse
Throttle Valve
Brake Adjustment
Screw
Gear End Fill
Plug
Motor End Fill
Plug
Motor End Drain Plug
Gear End Drain
Plug
Skid Mounting Bolts
Practices and Procedures
These practices and procedures have been prepared to provide the end user with basic
operating practices. This program does not include all safe working practices required in
specific lifting situations. The information is based on quality control procedures set by
Morgan City Rentals and should be performed by trained and experienced personnel.
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Always maintain and operate winch
in accordance with ANSI B30.9
safety code
Allow qualified, through training,
personnel to operate winch
Subject winch to regular inspection
and maintenance
Operator must understand proper
methods of hitching loads
Operator should have a knowledge
of attitude regarding safety
Operator should not operate under
unsafe conditions
Winches are not to be used for lifting
or lowering personnel
Hoist Inspection
Procedures
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Adhered to, recorded by, and directed by a qualified person
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Inspections done at the beginning of each shift or job
Items to be checked should included:
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Lubrication
Brakes
Wire Rope and Hooks or End Connections
Hoses, Connections, Brake Handle, Throttle Handle
Mounts (motor, bolts, and skid)
Anchor screws are NOT designed or intended
to hold any load/ weight
Air Hoist Inspection
Frequencies
Two classifications of Inspections
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–
Frequently
- Periodically
Frequently inspections are made by a qualified person to determine the degree
of exposure to wear, deterioration, or malfunction within respected
intervals.
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Normal Service – monthly
Heavy Service – weekly to monthly
Severe Service – daily to weekly
Periodically inspections are made to record external conditions to provide the
basis for a continuing evaluation.
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Normal Service – equipment in place - yearly
Heavy Service – equipment in place - yearly
Severe Service – equipment in place - quarterly
Hoist Maintenance
Procedures
Lubrication
Hose and Connections
Check
oil daily and maintain proper levels
Secure drain plugs and vent cap
Drain oil regularly and replace
Water will accumulate and cause blow-by
Use
Gear Lubrication
Mounting
be done every 60 – 90 days
Inspect gear end for sufficient signs of
lubrication
Add No. 1 grade gear grease to the grease
plug
Mount
Should
proper air hose connections and hose
safety clamp -1” crowfoot with safety clamp
Smaller hose and fittings will reduce
efficiency of the winch
For top performance operate winch at 90
psig (6.2 bar/620 kPa) air pressure
drum so that the axis of drum is
horizontal and vent cap is not more than 15
degrees off of top vertical
Check mounting bolts and base plate before
executing a lift
Air Hoist Pre Lift Operational Test
BU7A 1K Hoist
All test should be done by
trained qualified person
Visually inspect hoist before lift and
prepare a JSA with consideration to
the following items:
K5UL 6 K Hoist
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22 K IR Hoist
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Operator Qualifications
Cargo weights
Lifting, lowering, swing, and lift path
Containment and spill potential
Weight capacity limitations of hoist
Weather and site conditions
Operation of clutches, brakes, and
paws
Locking safety devices
Wire rope is correctly rated for hoist
Sheaves, and application
Wire rope anchor screw on drum
Stability and anchor points of hoist
Read all warning information on hoist
Air Hoist Safe
Operating Instructions
Before Each Daily Use of the Hoist
Start each use of hoist as if it is the first task of the job.
Never assume that the hoist is ready for use before
YOU do your INSPECTION
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Review the troubleshooting guide on common winch
symptoms , probable causes and remedies
Check all air hoses connections and do a pre-start
inspection on the power source (air compressor)
Make sure air supply is clean and free from moisture
Check air hoist position and mounting to surface
before use
Conduct a detail inspection all components (brake
lining and handle) and moving parts on hoist before
using hoist.
Make sure at least 3 wraps of wire are on the drum
before use and never have less than three wraps at all
times
Inspect wire and verify wire rope diameter to match
load
Make sure PPE is worn during operations
CAUTION –
Never perform maintenance while the
hoist is under a load. Disconnect
all air lines and tag before
maintenance. Air exhaust from the
motor can cause debris to fly.
Air Hoist Safe
Operating Instructions
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Never lift a load of unknown weight or weight
greater than winch capacity
Never use winch rope as a sling
Always stand clear of load and never carry
load over people
Insure clutch is fully engaged and do not
disengage clutch with load
Do not “side pull” or “yard” hoist
Do not operate with kinked, twisted, or
damaged wire
Make sure wire winds properly on drum
Standard Formula is 20 times winch diameter
for self winding
Ease slack out of wire when starting a lift. Do
not jerk or yank the load
Be sure no objects are in the way of load
Always test winch to MAX capacity with dead
pull to check rigging and winch mount tie
downs
Avoid shock loads
Any product will break if abused, misused,
overused, or not maintained properly
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Shut off air supply when winch is left
unattended
Be certain that load is seated in the saddle of
the hook
Do not divert attention away from a
suspended load
Do not use winch as a ground for welding or
attach a welding electrode to winch or sling
Do not leave load suspended for an extended
period of time-never unattended
Always check brake and lubrication before lift
Never - ever do anything you believe to be
unsafe
Do not swing a suspended load
If communication is lost with the operator
“All Stop”
If unsure of directions given, “ All Stop”
Operator can “STOP” lift at anytime if he feels
that it is unsafe
Attachments must have the same working
load as wire and hoist (clips, hooks,
shackles)
Air Hoist Safe
Operating Instructions
When paying out ensure wire is:
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Is smoothly paying out and drum is not over
running the wire rope, causing a slack wire
rope condition
Wire is seated in all sheaves and sheaves are
rotating with wire rope
Not making any unusual noises (snapping or
popping)
Not damaged or worn
Kept under tension to prevent loose wraps
Properly ensure in anchor screws and no less
than three wraps on the drum
When hauling-in ensure that wire rope is:
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Tightly wound on drum – use tension to keep
wraps tight
Spool onto drum evenly with no overlapping
Wire is seated in all sheaves and sheaves are
rotating with wire rope
Air Hoist Information Chart
For top performance and maximum durability, operate this
winch at 90 psi (6.2 bar/620 kPa) of air pressure
Air Consumption at 90 PSI
Hoist Model
BU7A
EU
HU, HUL
HU40, HUL40
H5U, H5UL
K4U, K4UL
K5U, K5UL
K6U, K6UL
UW50A30
25UWB1142
35UWD962
Pull Capacity
1000#
2000#
3000#
4000#
4000#
5000#
6000#
10000#
12000#
16000#
20000#
CFM Required
41
120
206
160
290
348
273
413
250
413
1400
Morgan City Rentals
Air Hoist
22,000 lbs. Air Hoist
6,250 lbs. Man-Rider Air Hoist
Model FA10140
Model FA525 MR
Make sure the right hoist is selected for the JOB!
Morgan City Rentals
28 K Air Hoist Capacities
Winch Model AW4A-40
Line Pull
W ire R ope dia
D rum W idth
La ye r N o.
AW4A-40
28,000 lbs.
1
2
3
4
5
6
7
8
9
10
11
28000.0 Line Spe e d
1
Le ngth, ft
40
6th La ye r
2940
N o. of
La ye rs
D rum D ia ., in 20 Fla nge D ia
10
D rum R pm
5.2
40.0
40.0
NOTE: VALUES WITHIN SHADED AREA
ARE IN ACCORDANCE
W/ ASME B30.7
UNSHADED AREA IS IN
COMPLIANCE W/ UK DEN.
N o. of
39
W ra ps
Ca pa cityAccumula te d Pitch
Ma x. H P
Fla nge
(ft)
Ca pa city D ia Line pull Spe e d Cle a ra nce
(ft)
(in)
(lbs)
(fpm)
214
232
250
267
285
303
321
338
356
374
391
214
446
696
964
1249
1552
1872
2211
2566
2940
3331
21
22.7
24.5
26.2
27.9
29.7
31.4
33.1
34.9
36.6
38.3
39554.67
36538.98
33950.56
31704.61
29737.37
28000.00
26454.43
25070.57
23824.29
22696.04
21669.83
28.4
30.7
33.1
35.4
37.8
40.1
42.4
44.8
47.1
49.5
51.8
9.0
8.1
7.3
6.4
5.5
4.7
3.8
2.9
2.1
1.2
0.3
Sta ll
Sta rt
Line Pull Line Pull
(lbs.)
(lbs.)
56119
51840
48168
44981
42190
39725
37533
35569
33801
32200
30744
43882
40536
37665
35173
32991
31063
29348
27813
26431
25179
24040
FPM
AT
F.S.
71
77
83
89
94
100
106
112
118
124
130
Air Hoist Models
Wire Capacities
Model
ANSI Half Drum Rating
lb
kg
Rope Speed at Rated Load
ft/min
m/min
Size and Maximum Length of Wire
Rope in Feet and Metres
(Diam.)
1/4"
6.5mm
5/16"
8mm
Weight without Wire Rope
lb
kg
Model
ANSIHalf Drum Rating
Rope Speed at Rated Load
Size and Maximum Lenth of Wire
Rope In Feet and Metres
Weight withou Wire Rope
lb
kg
ft/min
m/min
(Diam.)
7/16"
11mm
1/2"
13mm
5/8"
16mm
lb
kg
Model
ANSIHalf Drum Rating
BU7A
1000
454
45
14
Rope Speed at Rated Load
Size and Maximum Lenth of Wire
Rope In Feet and Metres
245
75
140
43
75
34
Weight without Wire Rope
K4U K4UL K5U K5UL
4000
4000 5000
5000
1814
1814 2268
2268
125
125 115
115
38
38
35
35
851
259
713
217
457
139
850
388
1741
531
1427
435
913
278
940
426
851
259
713
217
457
139
890
404
1741
531
1427
435
913
278
980
445
Series
ANSI Half Drum Rating
lb
kg
ft/min
m/min
(Diam.)
3/8"
10mm
7/16"
11mm
1/2"
13mm
lb
kg
lb
kg
Rope Speed at Rated Load
ft/min
m/min
Size and Maximum Length of Wire
Rope In Feet and Metres
(Diam.)
5/8"
16mm
3/4"
19mm
7/8"
22mm
Weight without Wire Rope
lb
kg
HU HUL
H5U H5UL HU40 HUL40
2500
2500 3000
3000
4000
4000
1134
1134 1361
1361
1814
1814
110
110 150
150
70
70
34
34
46
46
21
21
686
209
476
145
379
116
490
222
1445
440
1012
308
813
248
562
255
K6UA
686
209
476
145
379
116
525
258
K6UAL
1445
440
1012
308
813
248
598
271
686
209
476
145
379
116
525
238
1445
440
1012
308
813
248
600
272
7500
3402
70
21
K6U K6UL K6UL36
7500 10000
10000
10000
3402 4536
4536
4536
70
55
55
55
21
17
17
17
716
218
535
163
373
114
1315
596
1436
438
1070
326
775
236
1550
703
716
218
535
163
373
114
1315
596
1436
438
1070
326
775
236
1550
703
2119
646
1583
483
1159
353
2050
930
Air Hoist
Models Wire
Capacities
Model
ANSI Half Drum Rating
Rope Speed at Rated Load
Size and Maximum Length of Wire
Rope In Feet and Metres
Weight without Wire Rope
Model
ANSI Half Drum Rating
Rope Speed at Rated Load
Size and Maximum Length of Wire
Rope In Feet and Metres
Weight without Wire Rope
lb
kg
ft/min
m/min
12UWB1141K
14000
6350
20
6
12UWB1142K
14000
6350
20
6
25UWB1141K
14000
6350
45
14
25UWB1142K
14000
6350
45
14
(Diam.)
3/4"
19MM
7/8"
22MM
lb
kg
1754
535
1410
430
2100
945
2419
737
1918
585
2165
974
1754
535
1410
430
2100
945
2419
737
1918
585
2165
974
lb
kg
ft/min
m/min
35UWD962
20000
9072
30
9.1
(Diam.)
7/8"
22MM
1"
25MM
lb
kg
3026
922
2450
747
4190
1901
Never exceed working load limit
Keep out from under a raised
load
Avoid Shock Loads
Inspect hoist regularly
Service regularly
Wire Rope Spooling
Criteria
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When reeling wire rope from one reel to another, it is preferable for
the rope to travel from top to top
Hoist should be spooled with the recommended wire rope size.
Ensure tension is applied to wire rope when spooling onto drum
(approximately 10% of working load is recommended.
Cutting and seizing wire rope – should be properly seized on both
sides of the cut, if not wire will unravel. Use proper PPE when
working with wire
Do not install wire that has been overloaded or stretched
Make sure wire is properly attached to the drum with the set screws.
Wire rope anchors are not intended to retain the full load. Ensure
three wraps of wire are always on the drum. Less than three wraps
will allow rope anchors to loosen.
Keep tension on the wire while spooling on drum and guide each
wire close to the preceding wrap
After installation, allow wire to run through a cycle of operation at low
speed
ANSI ASME B 30.9
Safety Code
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Section 9-2.1: Construction
9-2.1.1 Wire Rope Material
The wire rope slings covered by this Chapter shall be as specified in
Tables 4 through 11 based upon nominal wire rope strength as shown
in Federal Specification RR-W-410 and Military Specification MIL-W83420 (except for fatigue requirements which are not applicable to
sling usage). Grades, types, sizes, and constructions other than those
specified in Tables 4 through 11 may be used. When such slings are
used, the sling manufacturer shall be consulted for specific data.
9-2.1.2 Minimum Sling Length
(a) Slings made of rope with 6 x 19 and 6 x 37 classification, and cable
laid slings shall have a minimum clear length of rope 10 times the rope
diameter between splices, sleeves, or end fittings.
(b) Braided slings shall have a minimum clear length of rope 40 times
the component (individual) rope diameter between the loops or end
fittings.
(c) Grommets and endless slings shall have a minimum circumferential
length of 96 times the body diameter of the grommet or endless sling.
9-2.4.1 All swaged-socket and poured-socket assemblies shall be
proof tested to the wire rope or fitting manufacturers recommendations
but in no case greater than 50% of the component wire ropes' or
structural strands' nominal strength. All other assemblies shall be proof
tested when specified by the purchaser. The proof load for swagedsocket and poured-socket assemblies shall be a minimum of two times
the vertical hitch rated load but shall not exceed 2.5 times the vertical
hitch rated load.
9-2.4.2 The proof load for single leg hand tucked slings shall be a
minimum of the vertical hitch rated load and shall not exceed 1.25
times the vertical hitch rated load.
9-2.4.3 The proof load for mechanical splice single leg slings and
endless slings shall be two times the vertical hitch rated load.
9-2.4.4 The proof load for multiple leg bridle slings shall be applied to
the individual legs and shall be either 1.25, for hand tucked splice, or
2, for mechanical splice, times the vertical
hitch rated load of a single leg sling of the same size, grade, and
construction of rope. Any master link to which multiple leg slings are
connected shall be proof loaded to two times the force applied by the
combined legs.
ANSI ASME B 30.9 Safety
Code
Section 9-2.5: Sling Identification
9-2.5.1 Marking Requirements. Each sling shall be marked to show:
(a) name or trademark of manufacturer,
(b) rated load for the type of hitch(es), and the angle upon which it is based,
(c) diameter or size
9-2.5.2 Sling identification shall be done by the sling manufacturer.
9-2.5.3 Maintenance of Sling Identification.
Sling identification should be maintained by the user so as to be legible during the life of the sling.
Section 9-2.6: Effects of Environment
9-2.6.1 Fiber core wire rope slings of all grades shall not be exposed to temperatures in excess of 180 °F (82°C).
9-2.6.2 When wire rope slings of any grade are to be used at temperatures above 400°F (204°C) or below -60 °F ( -51°C),
the sling manufacturer should be consulted.
9-2.6.3 The strength of slings can be affected by chemically active environments as sling materials may be susceptible
to damage from caustic or acid substances or fumes; strongly oxidizing environments attack all common sling
materials. The sling manufacturer should therefore be consulted before slings are used in chemically active
environments.
Section 9-2.7: End Attachments
9-2.7.1 All load bearing components welded prior to or after assembly in the sling shall be proof tested.
9-2.7.2 Welding of handles or any other accessories to end attachments, except covers to thimbles, shall be performed
prior to the assembly of the sling.
9-2.7.3 Knots. Eyes in wire rope slings shall not be formed using knots.
9-2.7.4 Wire Rope Clips and Hooks
9-2.7.4.1 Wire rope clips shall not be used to fabricate wire rope slings except where the application of slings prevents
the use of prefabricated slings or where the specific application is designed by a qualified person.
9-2.7.4.2 Slings made with wire rope clips should not be used as a choker hitch.
9-2.7.4.3 Wire rope clips shall be drop-forged steel of the single saddle (U-bolt) or double saddle type clip. Malleable cast
iron clips shall not be used. For spacing, number of clips, and torque values, refer to the clip manufacturer's
recommendation.
Air Hose - Safe Practices
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All hose assemblies should be viewed as potential hazards. This document is designed to inform and educate anyone who
manufactures, specifies, supplies, purchases, assembles, uses, maintains or tests any hose assemblies or its component parts. The
proper selection and maintenance of hose, couplings, attachment devices and accessories are imperative.
It is the end users responsibility to identify to the distributor the application and any special conditions that the hose assembly must
meet. It is the distributors responsibility to supply the proper assembly for the intended application. Accidents and down time may
occur if hose assemblies are not properly selected for the specific application.
The performance and safety of the assembly is affected by the quality of the individual components. The use of the acronym
S.T.A.M.P.E.D. (Size, Temperature, Application, Media, Pressure, Ends) will help in the proper selection of the hose assembly
components.
Failure to use these procedures can result in serious injury and destruction of property and
equipment.
When fabricating and specifying hose assemblies ask the following questions:
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Size: What is the I.D. (Inside Diameter) of the hose? What is the O.D. (Outside Diameter) of both ends of the hose? What is the
overall length of the assembly required?
Temperature: What is the temperature range of the media (product) that is flowing through the hose assembly? What is the
temperature range of the environment that surrounds the outside of the hose assembly?
Application: How is the hose assembly actually being used? Is it a pressure application? Is it a vacuum (suction) application? Is it a
gravity flow application? Are there any special requirements that the hose assembly is expected to perform? Is the hose being used
in a horizontal or vertical position? Are there any pulsations or vibrations acting on the hose assembly?
Media: What is the media/material that is flowing through the hose assembly? Being specific is critical. Check for: Abrasive
materials, chemical compatibility, etc.
Pressure: What is the maximum pressure including surges (or, maximum vacuum) that this hose assembly will be subjected to?
Always rate the maximum working pressure of your hose assembly by the lowest rated component in the system.
Ends: What couplings have been requested by the user? Are they the proper fittings for the application and hose selected?
Hose assemblies must be inspected prior to each use. Worn out fittings, attachment devices, hose
and accessory items must be replaced. Retaining devices (safety devices) such as clips, cables or
chains must be used. Clamps must be checked regularly to the specified torque found in the Dixon
literature. Under no circumstance should any coupling be disconnected while under pressure unless
the coupling is specifically designed to do so. Disconnecting couplings under pressure could result
in serious injury or death, and destruction to property and equipment.
Air Hose
Safe Practices
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Before attempting to disconnect the hose from the air line, the air should be cut off. Store hose
coils off the floor promptly after use. A safety-check valve installed in the air line at the
manifold will stop the air supply automatically if a line break occurs. A short chain fastened to
the hose and to the tool housing can keep the hose from thrashing about if a coupling breaks
Check to be sure the air hose is in good condition. Air hoses are designed to withstand
pressure, but they become weakened at points where they have been bent, where they are
attached to the shutoff valve and to the nozzle, and where they have been kinked. These
weak points may swell like a balloon and burst, throwing pieces of hose in every direction.
Always coiling the hose without kinks -- and hanging it over a broad support, not over a hook,
nail, or angle iron when it is not in use.
Air hoses
An air hose presents the same tripping or stumbling hazard as cords on electric tools. Persons
or materials accidentally hitting the hose may unbalance the operator or cause the tool to fall
from an overhead place;
Air hoses should be protected from trucks and pedestrians by runways or planks laid on either
side of the hose;
Do not disconnect an air hose from the tool being used, and use that air hose for cleaning
purposes;
Air should be cut off before attempting to disconnect the air hose from the line. Air pressure in
the hose should also be cleared before disconnecting;
Eye protection is required when operating air power tools. (See OP-G-1.3.2);
Safety-check valves are recommended to automatically shut off air supply if a crack or leak
occurs.
Air Hoists operating
in the Gulf of Mexico